Spunlace Line Control for Real-Time Gram Weight Stabilization
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Solution Overview
Problem
The current spunlace production line relies heavily on manual intervention for adjusting equipment parameters, leading to inefficiencies and instability due to subjective adjustments and time delays, particularly in managing gram weight fluctuations.
Innovation Solution
An intelligent control system that includes a data acquiring module, a data processing module, and a parameter control module, utilizing sensors, a time series database, and machine learning models like random forest and LSTM to predict gram weight fluctuations and automatically adjust cotton feeding roller parameters, establishing a closed-loop monitoring and adjustment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to adjust equipment parameters based on monitoring data, then the system can handle gram weight fluctuations, but the adjustment efficiency is low and there is time delay
Solution Approach 1:
The system enables self-service by implementing an automatic control loop where the computer automatically adjusts the cotton feeding roller parameters based on real-time gram weight monitoring data, eliminating the need for manual intervention and achieving timely, consistent parameter adjustments
Solution Approach 2:
The system implements feedback control by continuously monitoring gram weight parameters and automatically adjusting the cotton feeding roller parameters based on the monitored data, creating a closed-loop control system that responds dynamically to gram weight fluctuations
2Reliability
If manual intervention is used to adjust equipment parameters, then operators can respond to gram weight changes, but the adjustment is unstable due to subjective judgment
Solution Approach 1:
The system replaces the mechanical manual adjustment process with an automated computer-controlled system that objectively analyzes monitoring data and adjusts parameters according to predetermined rules, eliminating subjective judgment and ensuring consistent, reliable adjustments
3Manufacturing precision
If operators manually adjust cotton feeding parameters by observing online scanning curves, then gram weight can be controlled, but the process is laborious and not timely
Solution Approach 1:
The system performs self-service by automatically monitoring gram weight parameters and adjusting the cotton feeding roller parameters without requiring operators to observe curves or manually intervene, achieving both precise control and immediate response to gram weight changes
Data Source
AI summary
Disclosed is an intelligent control system of spunlace production line, which includes a data acquiring module, which is used for acquiring and storing real-time production line data; the production line data includes cotton feeding roller value, real-time moisture value, real-time speed value and real-time gram weight value; the data process module is used for classify and controlling that production line data, and giving the adjustment opinions of the cotton feeding roller parameters; the parameter control module is used for verifying the parameter adjustment opinions and applying the opinions to the control system; the data acquiring module, the data processing module and the parameter control module are connected in sequence.